Drapery fabrics

ABSTRACT

Stabilized, open-weave drapery fabrics having excellent surface coverage, high color intensity, and low light penetration per unit weight comprising (1) a wrap containing from about 16 to about 24 ends per inch of relatively flattened oval strip or ribbon saran having an average thickness of from about 1 1/2 mils to about 3 mils and an average width of from about 20 mils to about 35 mils and (2) a filling of flattened modacrylic yarns having a yarn size of from about 8/1 to about 4/1 cotton count, there being from about 12 to about 16 filling picks per inch.

United States Patent [19] Dean [ DRAPERY FABRICS [75] Inventor:

[73] Assignee:

[22] Filed:

[21] Appl.No.:

William Bruce Dean, Cornelia, Ga.

Johnson & Johnson, New Brunswick, N .J

May 7, 1974 Related US. Application Data [62] Division of Ser. No. 347,934, April 4, 1973.

[52] U.S.Cl [51] lnt.Cl.

................................... 139/420 R D03D 15/00 [58] Field of Search 139/420 R, 420 A, 426 R,

2,812,782 11/1957 Stevens 139/420 R 3,033,239 5/1962 Kenin 139/420 R 3,317,366 5/1967 Dionne 139/420 R 3,443,541 5/1969 Chopra 139/420 R 3,716,446 2/1973 Dean 139/420 R Primary ExaminerJames Kee Chi ABSIRACT Stabilized, open-weave drapery fabrics having excellent surface coverage, high color intensity, and low light penetration per unit weight comprising (1) a wrap containing from about 16 to about 24 ends per inch of relatively flattened oval strip or ribbon saran having an average thickness of from about 1% mils to about 3 mils and an average width of from about 20 mils to about 35 mils and (2) a filling of flattened modacrylic yarns having a yarn size of from about 8/ 1 to about 4/1 cotton count, there being from about 12 to about 16 filling picks per inch.

2 Claims, 4 Drawing Figures Zww/ US Patent Dec. 9, 1975 diam/05 T142 &.

DRAPERY FABRICS This patent application. is a division of copending patent application, Ser. No. 347,934, filed Apr. 4, 1973.,

Drapery fabrics include decorative and functional textile materials, such as curtains, drapes, hangings, and the like, which are generally suspended and hang loosely from rods, rails, hangers, hooks, and the like. Drapery fabrics should be light in weight but must possess sufficient weight properties as-to physically hang and drape properly. Drapery fabrics should also possess sufficient surface coverage, color intensity and low light penetration as to afford necessary aesthetic and functional characteristics and, of course, be economical to manufacture.

Many of these requirements are diametrically pposed to each other and drapery fabrics have therefore generally combined a compromise of most of these conflicting requirements. The purpose and object of the present invention is therefore to combine as many of these properties in drapery fabrics without substantially losing any one of the required or essential properties and characteristics.

It has been found that such purpose and object and others which will become clear from a further reading of this disclosure -may be achieved by. the improved methods of the present invention which involve weaving an open-weave drapery fabric from l) a warp containing from about 16 to about 24 ends per inch of relatively flattened oval strip or ribbon saran having an average thickness of from about 1 /2 mils to about 3 mils and an average width of from about 20 mils to about 35 mils and (2) a filling of modacrylic yarns having a yarn size of from about 8/ l to about 4/ l cottoncount, there being from about 12 to about 16 picks per inch; and calendering the resulting open-weave drapery fabric at elevated temperatures and under sufficient pressure as to soften, mold and generally flatten the filling yarns.

The resulting fabrics, when made into drapery fabrics, are found to possess the necessary properties and characteristics of good hanging and drape qualities, excellent surface coverage, color intensity and low light penetration per unit weight, along with excellent economy of man ufacture.

In the following specification and accompanying drawings, there are described and illustrated preferred embodiments of the invention but it is to be understood that the inventive concept is not to be considered limited to the embodiments disclosed except as determined by the scope of the appended claims. Referring to the accompanying drawings:

FIG. I is a fragmentary schematic flow chart depicting the manufacturing method of the present invention;

FIG. 2 is a cross section of one of the relatively flattened oval strip saran warp materials taken at right angles to the long axis of the flat strip;

FIG. 3 is a cross section of one of the modacrylic filling yarns prior to weaving and calendering, taken at right angles to the long axis of the filling yarn, showing its generally round or circular cross sections; and

FIG. 4 is a cross section of one of the modacrylic fill ing yarns subsequent to calendering, taken at right angles to the long axis of the filling yarn, showing its generally flattened cross section.

With reference to the drawings andparticularly FIG. 1 therein, there is schematically shown a conventional loom into which a warp sheet of relatively flattened The warp is made of saran ribbons of relatively flattened oval strip materials 12 having an average thickness of from about 1 /2 mils to about 3 mils and an average width:of.from-about 20 mils to about 35 mils. A typical cross section is shown in FIG. 2. The warp sheet contains from about 16 to about 24 ends per inch and is thus relatively an openly spaced warp. Its width is generally in the range of from about 30 inches to about 84 inches.

As used herein, the word saran is a generic term for a manufactured fiber in which the fiber-forming substance is any long chain synthetic polymer composed of at least per cent by weight of vinylidene chloride units (--Cl-I CCl Saran will not support combustion and is self-extinguishable. It has a specific gravity of 1.7, a moisture regain of only 0.1, a softening or sticking point of from about 240F. to about 320F., and a melting point of from about 335F. to about 350F.

Modacrylic filling yarns 14 are interwoven with the relatively flattened oval strip saran warp ribbons 12 in conventional weaving fashion and the resulting is an open-weave fabric 16.

Filling The filling yarns 14 are made of modacrylic yarns in the yarn size range of from about 8/1 to about 4/1 cotton count, or as is often stated 8's yarns single to 4s yam single. A typical round or circular cross section, prior to weaving, is shown in FIG. 2. Such yarn numbers, of course, indicate the number of hanks per pound, as is well known in the textile and related industries.

The filling yarns 14 are preferably spun from staple modacrylic fibers having an average denier of from about lto about 3, although bulked multifilamentary modacrylic yarns may also be used having a size and weight equivalent to the cotton count range set forth hereinabove. I

As used herein, the word modacrylic is the generic name for a manufactured fiber in which the fiber-forming substance is any long chain synthetic polymer composed of less than about 85 per cent, but at least about 35 per cent, by weight of acrylonitrile units except when the term qualifies as rubber or anidex. Dynel" is the most popular known trademark for modacrylic spun yarns, multifilaments, and monofilaments. Modacrylics will not support combustion and are self-extinguishable. They have specific gravities fromabout 1.30 to about 1.36, softening or sticking temperatures of from about 250F. to about 325F., which is considered as its moldable range.

The resulting fabric 16, when made up into drapery fabrics so that the warp of relatively flattened oval strip or ribbon saran materials hangs vertically, thus enhances the hanging and drape qualities and represents an excellent improvement over existing drapery fabrics. Such improvement is all the more increased when the fabric is exposed to a subsequent calendering process under heavy pressure ane elevated temperature for the purpose of flattening the modacrylic spun yarn into the plane of the drapery fabric. This flattening of the filling yarn and its molding into a relatively flattened cross-section, such as illustrated in FIG. 4 of the drawings, is a feature of the present invention.

Calendering As shown in FIG. 1, the open-weave fabric 16 is fed into a conventional calender l8. Calendering is essentially an ironing process wherein fabric is continuously run through the press nip of at least two rotating heated, pressure-applying rolls of a calender which is a heavy weight textile machine. One of the rotating rolls is usually made of a hard material such as chilled steel; the other roll is quite often made of a softer material. The rolls are adapted to be heated usually internally by gas, electric, or steam to any desired elevated temperature which in the present invention is sufficient to bring the fabric surface temperature into the range of from about 250F. to about 300F.

The rolls exert considerable pressure upon the fabric 16 passing therethrough, which, in the present invention, is in the range of from about tons to about 60 tons as exerted against a fabric having a width of about 48 inches, for example. Heavier calenders, capable of exerting up to 100 tons across the full width of the fabric may also be used, if desired, or required. The fabric passing through such calenders may move at a rate as low as about 50 yards per minute or less up to about 200 yards per minute or more depending upon the circumstances involved.

If desired, the fabric 16 may be passed through the nip several times for successive pressings and moldings. Following the calendering process, the calendered fabric 16' is then wound upon on take-up rolls at the back of the calendering machine.

During the calendering, the modacrylic filling yarns 14 which are originally more or less round or circular in cross section, as shown in FIG. 3, are flattened as shown in FIG. 4 so that they are more relatively flattened oval and lie more within the plane of the fabric and possess less or no tendency to roll or move out of or shift from the position as originally woven.

Additionally, these relatively flattened oval modacrylic filling yarns 14', with their relatively flat upper and lower surfaces, along with the flat surfaces of the flat strip saran warp 12 provide excellent surface coverage, high color intensity and low light penetration per unit weight of fabric.

And, it is also to be noted that the calendered fabric is flatter and more planar and yields a more pleasing view to the eye and a better hand.

The invention will be further illustrated in greater detail by the following specific examples. It should be understood, however, that although these examples may describe in particular detail some of the more specific features of the invention, they are given primarily for purposes of illustration and the invention in' its broader aspects is not to be construed as limited thereto.

EXAMPLE I Drapery fabric is made up to the following specifications: 2% mils X 28 mils saran relatively flattened oval strip warp, l8 ends per inch; 8/ l Dynel modacrylic filling yarns, polymerized from approximately 40 percent acrylonitrile and approximately 60 percent vinyl chloride, 14 picks per inch; weight of fabric is 0.226 pounds per linear yard; 48 inches wide. Calendering pressure is l-nip, 40 tons across the 48 inch width at a temperature of about 270F.

Drapery fabric made therefrom is stabilized and possesses excellent surface coverage, high color intensity and low light penetration per unit weight. It is flame retardant. Inspection of the fabric reveals that the modacrylic spun yarns are flattened and actually molded into a relatively flattened oval cross sectional shape in the plane of the fabric at the pressure and temperature which is exerted during calendering.

EXAMPLE II Drapery fabric is made up to the following specifications: 2% mils X 28 mils saran relatively flattened oval strip warp, l8 ends per inch; 6/1 Dynel modacrylic filling yarns(40 percent acrylonitrile and percent vinyl chloride); 14 picks per inch; weight of fabric is 0.287 pounds per linear yard; 48 inches wide. Calendering pressure is l-nip, 40 tons across the 48 inch width at a temperature of about 270F.

Drapery fabric made therefrom is stabilized and possesses excellent surface coverage, high color intensity and low light penetration per unit weight. It is flame retardant. Inspection of the fabric reveals that the modacrylic spun yarns are flattened and actually molded into an elliptical or oval cross sectional shape in the plane of the fabric at the pressure and temperature which is exerted during calendering.

EXAMPLE III Drapery fabric is made up to the following specifications: 2%. mils X 28 saran relatively flattened oval strip warp, l8 ends per inch; 4/l Dynel modacrylic filling yarns (40 percent acrylonitrile and 60 percent vinyl chloride), 14 picks per inch; weight of fabric is 0.336 pounds per linear yard; 48 inches wide. Calendering pressure is l-nip, 40 tons across the 48 inch width at a temperature of about 270F.

Drapery fabric made therefrom is stabilized and possesses excellent surface coverage, high color intensity and low light penetration per unit weight. It is flame retardant. Inspection of the fabric reveals that the modacrylic spun yarns are flattened and actually molded into a relatively flatly elliptical or oval cross sectional shape in the plane of the fabric at the pressure and temperature which is exerted during calendering.

Although several specific examples of the inventive concept have been described, the same should not be construed as limited thereby nor to the specific features mentioned therein but to include various other equivalent features as set forth in the claims appended hereto. It is understood that any suitable changes, modifications and variations may be made without departing from the spirit and scope of the invention.

What is claimed is:

l. A stablilized open-weave drapery fabric having excellent surface coverage, high color intensity and low light penetration per unit weight comprising: (l) a warp containing from about 16 to 24 ends per inch of relatively flat oval strip saran having an average thickness of from about l /z mils to about 3 mils and an average width of from about 20 mils to about 35 mils and (2) a filling of flattened oval modacrylic yarns having a yarn size of from 8/1 to about 4/1 cotton count, said filling yarns being molded into the flattened oval crosssectional shape in the plane of the fabric whereby there is no tendency of said filling yarns to roll, shift or move out of their positions as originally woven, there being from about 12 to about 16 picks per inch.

2. A stabilized open-weave drapery fabric as defined in claim 1 wherein the modacrylic filling yarn is Dynel, a copolymer of about 40 percent by weight acrylonitrile and about 60 percent by weight vinyl chloride. 

1. A STABILIZED OPEN-WAVE DRAPERY FABRIC HAVING EXCELLENT SURFACE COVERAGE, HIGH COLOR INTENSITY AND LOW LIGHT PENETRATION PER UNIT WEIGHT COMPRISING: (1) A WARP CONTAINING FROM ABOUT 16 TO 24 ENDS PER INCH OF RELATIVELY FLAT OVAL STRIP SARAN HAVING AN AVERAGE THICKNESS OF FROM ABOUT 1 1/2 MILS TO ABOUT 3 MILS AND AN AVERAGE WIDTH OF FROM ABOUT 20 MILS TO ABOUT 35 MILS AND (2) A FILLING OF FLATTENED OVAL MODACRYLIC YARNS HAVING YARN SIZE OF FROM 8/1 TO ABOUT 4/1 COTTON COUNT, SAID FILLING YARNS BEING MOLDED INTO THE FLATTENED OVAL CROSS-SECTION L SHAPE IN THE PLANE OF THE FABRIC WHEREBY THERE IS NO TENDENCY OF SAID FILLING YARNS TO ROLL, SHIFT OR MOVE OUT OF THEIR POSITION AS ORIGINALLY WOVEN, THERE BEING FROM ABOUT 12 TO ABOUT 16 PICKS PER INCH.
 2. A stabilized open-weave drapery fabric as defined in claim 1 wherein the modacrylic filling yarn is Dynel, a copolymer of about 40 percent by weight acrylonitrile and about 60 percent by weight vinyl chloride. 